Self Venting Setting Tool That Utilizes Wellbore Fluid to Dampen Setting Motion

ABSTRACT

A setting tool for setting a device within a wellbore. The setting tool includes first and second chambers within a housing. A piston separates the chambers and is moveable within the second chamber. The piston is initially positioned adjacent a first end of the second chamber. The setting tool includes a first aperture in communication with the second chamber. Wellbore fluid may enter the second chamber through the first aperture. As the piston moves towards the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the first aperture. Pressure within the first chamber vents from the first chamber through the first aperture when the piston moves past the first aperture within the second chamber. The housing may include a second aperture adjacent to the second end of the second chamber that permits wellbore fluid to enter and exit.

BACKGROUND Field of the Disclosure

The embodiments described herein relate to apparatuses, systems, and methods for damping the movement of a piston within a setting tool with wellbore fluid and venting the pressure created by the detonation of a power charge within the setting tool.

Description of the Related Art

A downhole setting tool may use a power charge to set a device within a wellbore. The power charge is detonated to generate the force required to set the device. For example, the force from the detonated power charge may move a piston causing the setting of the device. The power charge of the downhole setting tool may be used to set various devices in a wellbore as would be appreciated by one of ordinary skill in the art. For example, a downhole setting tool with a power charge may be used to set bridge plugs, cement retainers, packers, and various other downhole devices.

The force created by the detonation of the power charge can be significant. Present downhole setting tools typically use oil contained within a cylinder to dampen the force and decrease the movement of a piston due to the detonation of the power charge. The use of oil within the setting tool may require a longer length of the setting tool than a setting tool that does not include a dampening feature. In some applications, a shorter tool may be preferred. The use of oil within the setting tool may also require the removal of the oil from the wellbore and/or the from the downhole setting tool. Another issue with downhole setting tools is the venting of the pressure within the setting tool after the detonation of the power charge. It is undesirable to bring a downhole setting tool to the surface with pressure from the detonation of the power charge still contained within a portion of the setting tool. Other disadvantages may exist.

SUMMARY

The present disclosure is directed to apparatuses, systems, and methods for damping the movement of a piston within a setting tool with wellbore fluid and venting the pressure created by the detonation of a power charge within the setting tool.

An embodiment of the present disclosure is a setting tool comprising a housing having a first chamber and a second chamber. The setting tool includes a piston positioned within the housing. The piston separates the first chamber from the second chamber. The second chamber has a first end and a second end, wherein the piston is initially positioned adjacent to the first end of the second chamber and wherein the piston is moveable within the second chamber. The setting tool includes a rod connected to the piston. The setting tool includes a first aperture through the housing in between the first and second ends of the second chamber, the first aperture in communication with the second chamber. Wellbore fluid may enter the second chamber through the first aperture. As the piston moves from the first end of the second chamber towards the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the first aperture. Pressure within the first chamber vents from the first chamber through the first aperture when the piston moves past the first aperture within the second chamber.

The setting tool may include a second aperture through the housing, the second aperture is in communication with the second chamber. Wellbore fluid may enter the second chamber through the second aperture. As the piston moves from the first end of the second chamber towards the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the second aperture. The pressure within the first chamber does not vent through the second aperture. The second aperture may be positioned between the first aperture and the second end of the second chamber. The second aperture may be positioned adjacent to the second end of the second chamber. The rod may be connected to a device to be set within a wellbore. The device may be a packer, bridge plug, cement retainer, or the like. Movement of the piston within the second chamber in a direction away from the first chamber sets the device in a wellbore.

An embodiment of the present disclosure is a system for setting a device within a wellbore. The system includes a housing having a first chamber and a second chamber with a power charge positioned within the first chamber. The system includes a piston positioned within the housing. The piston separates the first chamber from the second chamber, the second chamber having a first end and a second end. The piston is initially positioned adjacent to the first end of the second chamber and the piston is moveable within the second chamber. A rod is connected to the piston. The system includes a first aperture through the housing, the first aperture is in communication with the second chamber. Wellbore fluid is positioned within the second chamber that entered the second chamber through the first aperture. Upon detonation of the power charge, pressure from the detonation moves the piston from the first end of the second chamber towards the second end of the second chamber. Wellbore fluid within the second chamber dampens the movement of the piston and is forced out of the second chamber through the first aperture as the piston moves from the first end to the second end of the second chamber. Pressure within the first chamber from the detonation of the power charge vents from the housing through the first aperture when the piston moves past the first aperture within the second chamber.

The system may include a second aperture through the housing, the second aperture is in communication with the second chamber. A portion of the wellbore fluid within the second chamber may have entered into the second chamber through the second aperture. As the piston moves from the first end to the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the second aperture. Pressure within the first chamber from the detonation of the power charge cannot vent through the second aperture. The second aperture may be positioned between the first aperture and the second end of the second chamber and the second aperture may be positioned adjacent to the second end of the second chamber. The system may include a device connected to the rod, wherein the device is set within the wellbore upon movement of the piston from the first end to the second end of the second chamber.

An embodiment of the present disclosure is a method comprising providing a setting tool having a first chamber, a second chamber, and a piston moveable within the second chamber, wherein the piston separates the first chamber from the second chamber. The method includes providing a first aperture in the setting tool in communication with the second chamber, wherein the first aperture permits wellbore fluid to enter into the second chamber. The method includes moving the piston from a first end to a second end of the second chamber to set a device within the wellbore. The method includes dampening the movement of the piston with wellbore fluid within the second chamber, wherein wellbore fluid exits the second chamber through the first aperture as the piston moves towards the second end of the second chamber. The method includes venting the first chamber as the piston moves past the first aperture.

The method may include providing a second aperture in the setting tool in communication with the second chamber. The method may include isolating the second aperture from the first chamber, wherein the second aperture permits wellbore fluid to enter into the second chamber and wherein wellbore fluid exits the second chamber through the second aperture as the piston moves toward the second end of the second chamber. The method may include providing a power charge within the first chamber of the setting tool. The method may include detonating the power charge within the first chamber to move the piston from the first end to the second end of the second chamber, wherein pressure created from the detonation of the power charge vents from the setting tool as the piston moves past the first aperture. The method may include controlling a velocity of the piston as it moves within the second chamber. Controlling the velocity of the piston may include configuring a first area of the first aperture and configured a second area of the second aperture to control the velocity of the piston.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic of an embodiment of a setting tool.

FIG. 2 shows a schematic of an embodiment of a setting tool.

FIG. 3 shows a schematic of an embodiment of a setting tool.

FIG. 4 shows a schematic of an embodiment of a setting tool positioned within a wellbore.

FIG. 5 shows a schematic of an embodiment of a setting tool positioned within a wellbore.

FIG. 6 shows a schematic of an embodiment of a setting tool positioned within a wellbore.

FIG. 7 is a flow chart of one embodiment of a method disclosure herein.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

FIG. 1 shows an embodiment of a setting tool 100. The setting tool includes multiple housing sections 110A, 110B, 110C that collectively form a housing 110 (best shown in FIGS. 4-6). The number of housing sections 110A, 100B, 110C are shown for illustrative purposes only and may be varied as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the setting tool 100 may be formed from a single integral housing, but the use of multiple housing sections, such as, but not limited to, 110A, 110B, 110C may aid in the manufacturing of the setting tool 100.

The setting tool 100 includes a first chamber 120 and a second chamber 130. A piston 140 is positioned within the housing 110 of the setting tool 100. The piston 140 separates the first chamber 120 from the second chamber 130. Seals 141 located on the outside of piston 140 hydraulic isolate the first chamber 120 from the second chamber 130. The piston 140 is moveable within the second chamber 130 as discussed herein. The housing 110 includes a first aperture 160 through the housing 110. Specifically, the first aperture 160 may be through housing section 110B and provides communication with the second chamber 130 from outside of the setting tool 100. The second chamber 130 includes a first end 131 and a second end 132 with the piston 140 being positioned in an initial positioned adjacent to the first end 131 of the second chamber 130.

A rod 150 is connected to the piston 140 and may be used to set a device 300 (shown in FIGS. 4-6) in a wellbore 1 (shown in FIG. 1). An end 151 of the rod 150 is configured to set to a connector 190 that is configured to connect to and set the device 300 in the wellbore 1. The movement of the piston 140 and rod 150 sets the device 300 in the wellbore 1 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.

As the setting tool 100 is positioned into a wellbore 1, wellbore fluid may enter into the second chamber 130 through the first aperture 160 as indicated by arrow Win. Substantially the entire second chamber 130, if not the entire second chamber 130, will be filled will wellbore fluid as the setting tool 100 is run into the wellbore 1 and positioned at a desired location within the wellbore 1. The wellbore fluid positioned within the second chamber 130 dampens the movement of the piston 140 as discussed herein. The use of wellbore fluid within the second chamber 130 enables the setting tool 100 to have a shorter stroke than prior art setting tools that use oil within a cylinder to dampen the movement of the piston due to the detonation of a power charge.

The housing 110 may include a second aperture 170 through the housing 110. Specifically, the second aperture 170 may be through housing section 110B and provides communication with the second chamber 130 from outside of the setting tool 100. The second aperture 170 is positioned between the first aperture 160 and the second end 132 of the second chamber 130. The second aperture 170 may be positioned adjacent to the second end 132 of the second chamber 130. As the setting tool 100 is positioned into a wellbore 1, wellbore fluid may also enter into the second chamber 130 through the second aperture 170 as indicated by arrow Win. Substantially the entire second chamber 130, if not the entire second chamber 130, will be filled will wellbore fluid as the setting tool 100 is run into the wellbore 1 and positioned at a desired location within the wellbore 1. The wellbore fluid positioned within the second chamber 130 dampens the movement of the piston 140 as discussed herein

A power charge 200 may be positioned within the first chamber 120 of the setting tool 100. FIG. 1 shows the piston 140 in its initial position being adjacent to the first chamber 120. With the piston 140 in the initial position, wellbore fluid will file the second chamber 130 through first and second apertures 160, 170 as the setting tool 100 is run into a wellbore 1 as indicated by arrows Win. The power charge 200 may be detonated downhole to move the piston 140 and rod 150 to set a device within the wellbore 1 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.

FIG. 2 shows the piston 140 moving from the first end 131 toward the second end 132 of the second chamber 130 due to pressure P created by the detonation of the power charge 200 (shown in FIG. 1) located within the first chamber 120 of the setting tool 100. As the piston 140 moves from its initial positioned adjacent to the first end 131 of the second chamber 130 toward the second end 132 of the second chamber 130, the wellbore fluid within the second chamber 130 will be forced out of the second chamber 130 through the first and second apertures 160, 170 as indicated by arrows Wout.

The wellbore fluid exiting the second chamber 130 at a controlled rate dampens the movement of the piston 140, and the attached rod 150, due to the pressure P from the detonation of the power charge 200. The size of the apertures 160, 170 as well as the number of the apertures 160, 170 may be configured to control the velocity of the piston 140. For example, decreasing the size (i.e. area) and/or number of the apertures 160, 170 decreases the rate at which the wellbore fluid may escape the second chamber 130, thus increasing the dampening of the velocity of the piston 140 due to the detonation of the power charge 200. Likewise, increasing the size (i.e. area) and/or number of the apertures 160, 170 increases the rate at which the wellbore fluid may escape the second chamber 130, thus decreasing the dampening of the velocity of the piston 140 due to the detonation of the power charge 200.

FIG. 3 shows the piston 140 has moved past the first aperture 160 within the second chamber 130. Once the piston 140 moves past the first aperture 160, the pressure P due to the detonation of the power charge 200 is vented to the wellbore through the first aperture 160 as indicated by arrow Pout. The first aperture 160 provides multiple functions for the setting tool 100. The first aperture 160 permits wellbore fluid to enter the second chamber 130 and later exit the second chamber 130 to dampen the movement of the piston 140 due to the detonation of a power charge 200. Additionally, the first aperture 160 vents the P due to the detonation of a power charge 200 from within the setting tool 100 as the piston 140 moves past the first aperture 160. Thus, the setting tool 100 will be safe when returned to the surface at setting a device 300 within a wellbore 1.

Even as the pressure P is vented through the first aperture, the wellbore fluid located within the second chamber 130 may still exit through the second aperture 170 as indicated by arrow Wout shown in FIG. 3. As the second aperture 170 is located adjacent to the second end 132 of second chamber 130, wellbore fluid may be force out of the second chamber 130 enabling the piston 140 to reach the second end 132 of the second chamber 130. The second aperture 170 permits wellbore fluid to enter the second chamber 130 and later exit the second chamber 130 to dampen the movement of the piston 140 due to the detonation of a power charge 200. However, the pressure P created by the detonation of the power charge 200 cannot vent through the second aperture 170. Seals 141 on the exterior of the piston 140 isolate the second aperture 170 from the first chamber 120 and the pressure P created by the detonation of the power charge 200.

The number, size, location, and/or configuration of the first and second apertures 160, 170 are shown in FIGS. 1-3 for illustrative purposes and may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the size and/or number of the apertures 160, 170 may be varied to change the dampening effect of the wellbore fluid located within the second chamber 130 as the piston 140 move from the first end 131 to the second end 132 of the second chamber 130.

FIG. 4 shows an embodiment of a setting 100 positioned within a wellbore 1. A device 300 is connected to the end of the setting tool 100 via a connector 190. The connector 190 couples the device 300 to the piston 140 and rod 150. FIG. 4 shows the piston 140 in the initial position within the second chamber 130 prior to the detonation of a power charge 200 located within the first chamber 120 of the setting tool 100. The second chamber 130 will be filled with wellbore fluid as the setting tool 100 is run into the wellbore via the first and second apertures 160, 170.

FIG. 5 shows the piston 140 moved to the second end 132 of the second chamber 130 via the detonation of the power charge 200. The movement of the piston 140 sets the device 300 in the wellbore 1. The device 300 may be a packer, bridge plug, cement retainer, or the like, as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Wellbore fluid within the second chamber 130 exits the second chamber 130 during the movement of the piston 140 within the second chamber 130 as discussed herein. The wellbore fluid with the second chamber 130 dampens the movement of the piston 140 due to the detonation of the power charge (shown in FIG. 4). The dampening effect of the wellbore fluid within the second chamber 130 may be modified by varying the number and/or size of the first and second apertures 160, 170 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. The pressure within the setting tool 100 that moves the piston 140 is vented into the wellbore via the first aperture 160 once the piston 140 moves within the second chamber 130 past the first aperture 160. The piston 140 isolates the second aperture 170 from the first chamber 120 and the pressure created by the detonation of the power charge 200.

FIG. 6 shows the setting tool 100 disconnected from the device 300 with the device 300 set within the wellbore 1. As discussed herein, the device 300 is settable by the movement of the piston 140 due to the detonation of a power charge 200 within the setting tool 100. With the internal pressure vented from the setting tool 100, the setting tool 100 may be safely removed from the wellbore 1 while the device 300 remains set within the wellbore 1. The device 300 may be, but is not limited to, a packer, bridge plug, cement retainer, or the like.

FIG. 7 is a flow chart of one embodiment of a method 400 of the present disclosure. The method 400 includes providing a setting tool having a first chamber, a second chamber, and a piston moveable within the second chamber, wherein the piston separates the first chamber from the second chamber, at 410. The method 400 includes providing a first aperture in the setting tool in communication with the second chamber, wherein the first aperture permits wellbore fluid to enter into the second chamber, at 420. For example, as the setting tool 100 is run into a wellbore 1 the wellbore fluid within the wellbore may enter into the second chamber 130 via the first aperture 160.

The method 400 includes moving the piston from a first end to a second end of the second chamber to set a device within the wellbore, 430. The method 400 includes dampening the movement of the piston with wellbore fluid within the second chamber, wherein wellbore fluid exits the second chamber through the first aperture as the piston moves towards the second end of the second chamber, at 440. For example, wellbore fluid is forced out of the second chamber 130 through the first aperture 160 as the piston 140 of the setting tool 100 moves within the second chamber 130. The method 400 includes venting the first chamber as the piston moves past the first aperture, at 450.

The method 400 may include providing a second aperture in the setting tool in communication with the second chamber, at 421. The method 400 may include isolating the second aperture from the first chamber, wherein the second aperture permits wellbore fluid to enter into the second chamber and wherein wellbore fluid exits the second chamber through the second aperture as the piston moves toward the second end of the second chamber, at 422. For example, seals 141 on the exterior of the piston 140 may isolate the second aperture 170 from pressure P created due to the detonation of a power charge 200.

The method 400 may include providing a power charge within the first chamber of the setting tool, at 423. The method 400 may include detonating the power charge within the first chamber to move the piston from the first end to the second end of the second chamber, wherein pressure created from the detonation of the power charge vents from the setting tool as the piston moves past the first aperture, at 424. The method 400 may include controlling a velocity of the piston as it moves within the second chamber, at 441. For example, the wellbore fluid contained within the second chamber 130 of the setting tool 100 may damped and thus, control the velocity of the piston 140 after detonation of the power charge 200. The method 400 may include controlling the velocity of the piston by configuring a first area of the first aperture and configured a second area of the second aperture to control the velocity of the piston, at 442

Although this disclosure has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Accordingly, the scope of the present disclosure is defined only by reference to the appended claims and equivalents thereof. 

What is claimed is:
 1. A setting tool comprising: a housing having a first chamber and a second chamber; a piston positioned within the housing, the piston separates the first chamber from the second chamber, the second chamber having a first end and a second end, wherein the piston is initially positioned adjacent to the first end of the second chamber and wherein the piston is moveable within the second chamber; a rod connected to the piston; a first aperture through the housing in between the first and second ends of the second chamber, the first aperture in communication with the second chamber; wherein wellbore fluid may enter the second chamber through the first aperture; wherein as the piston moves from the first end of the second chamber towards the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the first aperture; and wherein pressure within the first chamber vents from the first chamber through the first aperture when the piston moves past the first aperture within the second chamber.
 2. The setting tool of claim 1, further comprising a second aperture through the housing, the second aperture in communication with the second chamber, wherein wellbore fluid may enter the second chamber through the second aperture.
 3. The setting tool of claim 2, wherein as the piston moves from the first end of the second chamber towards the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the second aperture.
 4. The setting tool of claim 3, wherein pressure within the first chamber does not vent through the second aperture.
 5. The setting tool of claim 3, wherein the second aperture is positioned between the first aperture and the second end of the second chamber.
 6. The setting tool of claim 3, wherein the second aperture is positioned adjacent to the second end of the second chamber.
 7. The setting tool of claim 3, wherein the rod is connected to a device.
 8. The setting tool of claim 7, wherein the device comprises a packer, bridge plug, or cement retainer.
 9. The setting tool of claim 7, wherein movement of the piston within the second chamber in a direction away from the first chamber sets the device in a wellbore.
 10. A system for setting a device within a wellbore comprising: a housing having a first chamber and a second chamber; a power charge positioned within the first chamber; a piston positioned within the housing, the piston separates the first chamber from the second chamber, the second chamber having a first end and a second end, wherein the piston is initially positioned adjacent to the first end of the second chamber and wherein the piston is moveable within the second chamber; a rod connected to the piston; a first aperture through the housing, the first aperture in communication with the second chamber; wellbore fluid within the second chamber, wherein wellbore fluid entered the second chamber through the first aperture; wherein upon detonation of the power charge, pressure from the detonation moves the piston from the first end of the second chamber towards the second end of the second chamber, wellbore fluid within the second chamber dampens movement of the piston and is forced out of the second chamber through the first aperture as the piston moves from the first end to the second end of the second chamber; and wherein pressure within the first chamber from the detonation of the power charge vents from the housing through the first aperture when the piston moves past the first aperture within the second chamber.
 11. The system of claim 10, further comprising a second aperture through the housing, the second aperture in communication with the second chamber, wherein a portion of the wellbore fluid within the second chamber entered into the second chamber through the second aperture.
 12. The system of claim 11, wherein as the piston moves from the first end to the second end of the second chamber, wellbore fluid within the second chamber is forced out of the second chamber through the second aperture.
 13. The system of claim 12, wherein pressure within the first chamber from the detonation of the power charge does not vent through the second aperture.
 14. The system of claim 13, wherein the second aperture is positioned between the first aperture and the second end of the second chamber and wherein the second aperture is positioned adjacent to the second end of the second chamber.
 15. The system of claim 14, further comprising a device connected to the rod, wherein the device is set within the wellbore upon movement of the piston from the first end to the second end of the second chamber.
 16. A method comprising: providing a setting tool having a first chamber, a second chamber, and a piston moveable within the second chamber, wherein the piston separates the first chamber from the second chamber; providing a first aperture in the setting tool in communication with the second chamber, wherein the first aperture permits wellbore fluid to enter into the second chamber; moving the piston from a first end to a second end of the second chamber to set a device within the wellbore; dampening the movement of the piston with wellbore fluid within the second chamber, wherein wellbore fluid exits the second chamber through the first aperture as the piston moves toward the second end of the second chamber; and venting the first chamber as the piston moves past the first aperture.
 17. The method of claim 16, further comprising: providing a second aperture in the setting tool in communication with the second chamber; and isolating the second aperture from the first chamber, wherein the second aperture permits wellbore fluid to enter into the second chamber and wherein wellbore fluid exits the second chamber through the second aperture as the piston moves toward the second end of the second chamber.
 18. The method of claim 17, further comprising: providing a power charge within the first chamber of the setting tool; and detonating the power charge within the first chamber to move the piston from the first end to the second end of the second chamber, wherein pressure created from the detonation of the power charge vents from the setting tool as the piston moves past the first aperture.
 19. The method of claim 18, further comprising controlling a velocity of the piston as it moves within the second chamber.
 20. The method of claim 19, wherein controlling the velocity of the piston further comprises configuring a first area of the first aperture and configured a second area of the second aperture to control the velocity of the piston. 